LED lighting element and method of manufacturing same

ABSTRACT

A lighting element is disclosed that provides a projection of light forming a substantially uniform bright light on a surface a known distance from the lighting element. The lighting elements includes a dome lens that is removably positioned on a light source, such that the light source is retained at a location within a focal length of a projection lens and at or within a focal length of the dome lens. The dome lens magnifies the light outputted by the light source, such that the projected light is brighter than the light generated by the light source.

CLAIM OF PRIORITY

This application claims, pursuant to 35 USC 120, as aContinuation-in-Part Application, priority to, and the benefit of theearlier filing date of patent application Ser. No. 16/693,212 filed onNov. 22, 2019, which claimed as a Continuation application, priority to,and the benefit of the earlier filing date of patent application Ser.No. 16/275,308 (U.S. Pat. No. 10,527,254) filed on Feb. 13, 2019, whichclaimed, pursuant to 35 USC 120, as a Continuation application priorityto and the benefit of the earlier filing date of patent application Ser.No. 15/921,217 (U.S. Pat. No. 10,237,384) filed on Mar. 14, 2018, whichclaimed priority to, and the benefit of the earlier filing date of,provisional applications Ser. No. 62/561,125 filed on Sep. 20, 2017 and62/502,602 filed on May 6, 2017, the contents of all of which areincorporated by reference, herein.

RELATED APPLICATIONS

This application is related to the teaching of U.S. Pat. Nos. 7,690,806,8,215,791, RE46,463, and 9,791,138, which are assigned to the sameAssignee as that of the instant application, and whose contents areincorporated by reference, herein.

FIELD OF THE INVENTION

The instant application relates to the field of optics and moreparticularly to a lighting element and light assembly having increasedillumination output.

BACKGROUND OF THE INVENTION

Professionals, such as operating room doctors, surgeons, dentists,hygienists, EMT, mechanics, etc., require light to provide adequateillumination to the operating field. Having this light coming from thepoint of view of the user allows for shadow-free operation. Thetechnology for providing the medical field, for example, thisillumination is dominated by battery powered headlights and overheadlighting that allow the user to direct a light output onto a surface theuser is looking at.

In addition, it is advantageous for the light that is projected onto thesurface be as uniformly distributed as possible.

Light emitting diodes (LEDs) are becoming a predominate source of light,as they are light-weight, require less power, and provide a whiter lightthan conventional incandescent or halogen lights. However, newergeneration LED technology provides for smaller LED packaging, which inturn reduces the light output of each LED. That is, as the efficiency ofLED technology has increased, LED die are continually being madesmaller. However, this smaller size makes the total light output of theLED (or LED package) to be less than that of conventional LEDs.

To compensate for the reduced size (and reduced output), generally thenumber of LEDs included within a light package that operates as a lightsource need to be increased to provide a projected light size that iscomparable to the older LED technology. However, the increased number ofrequired LEDs causes the projected light to be displayed to show theincreased number of LED images. In addition, as it is known in the art,LED light output is dependent upon a current (or voltage) applied to theLED. To increase the brightness of newer generation of LEDs, an increasein the current applied to the new generation LEDs is necessary. However,as the current output of the battery is increased, the duration of theusable output decreases.

Hence, there is a need in the industry for a light assembly thatprovides a substantially uniform bright light on a surface withoutincreasing the current to the LED, which reduces the life expectancy ofthe device.

SUMMARY OF THE INVENTION

A lighting element (or device) for providing an increased outputillumination without the need for an increased power (voltage/current)input is disclosed.

A method for manufacturing a lighting element providing an increasedoutput illumination without the need for an increased power output isdisclosed.

In one aspect of the invention, an LED (or LED array) is positionedwithin or at the focal length of a short focal length dome magnifier andconcurrently within a focal length of a longer length magnificationlens, such that the projection of the light from the LED (or LED array)is substantially uniform.

In one aspect of the invention, an aperture may be incorporated betweenthe dome magnifier and the LED such that stray light is avoided in theprojected light.

In one aspect of the invention, a method for positioning the LED withinthe focal length of the dome magnifier is disclosed.

In one aspect of the invention, a heat sink is incorporated into ahousing of the device to remove heat generated by the LED (or the LEDarray).

In one aspect of the invention, the dome magnifier is proximate to, orin contact with, the LED (or LED array) without the use of adhesivematerials. The non-use of adhesive materials is advantageous as itprevents lens fogging due to any out-gassing of the heated adhesivematerial.

In accordance with the principles of the invention, a lighting elementwith an increased illumination output may be incorporated into aself-contained, battery operated, lighting unit.

In accordance with the principles of the invention, a light assemblyincluding a lighting element having an increased illumination intensitymay be attached to an eyewear, a headband or a head-strap to provide asubstantially uniform light on a plane that the eye is focused on.

In accordance with the principles of the invention, a light assemblyincluding a lighting element having an increased illumination intensitymay be incorporated into a stand-alone device, such as an overhead lamp,a table lamp, a flashlight, and similar lighting devices, wherein asubstantially uniform light is projected onto a surface.

BRIEF DESCRIPTION OF THE FIGURES

For a better understanding of exemplary embodiments and to show how thesame may be carried into effect, reference is made to the accompanyingdrawings. It is stressed that the illustrative embodiments shown are byway of example only and for purposes of illustrative discussion of thepreferred embodiments of the present disclosure and are presented in thecause of providing what is believed to be the most useful and readilyunderstood description of the principles and conceptual aspects of theinvention. In this regard, no attempt is made to show structural detailsof the invention in more detail than is necessary for a fundamentalunderstanding of the invention, the description taken with the drawingsmaking apparent to those skilled in the art how the several forms of theinvention may be embodied in practice. In the accompanying drawings:

FIG. 1 illustrates a perspective view of a light assembly in accordancewith the principles of the invention.

FIG. 2 illustrates a cross-sectional view of a light assembly inaccordance with the principles of the invention.

FIG. 3A illustrates an exemplary front view of a circuit board containedwithin the housing shown in FIG. 1 .

FIG. 3B illustrates a second aspect of the exemplary front view of acircuit board shown in FIG. 3A.

FIG. 3C illustrates a third aspect of the exemplary front view of acircuit board shown in FIG. 3B.

FIG. 3D illustrates an exemplary rear view of a circuit board shown inFIG. 3D.

FIG. 4A illustrates an exemplary dome lens in accordance with theprinciples of the invention.

FIG. 4B illustrates exemplary characteristics of the dome lens shown inFIG. 4A.

FIG. 4C illustrates a second exemplary dome lens in accordance with theprinciples of the invention.

FIG. 4D illustrates a third exemplary dome lens in accordance with theprinciples of the invention.

FIG. 4E illustrates exemplary characteristics of the dome lens shown inFIG. 4D.

FIG. 5A illustrates a side view of an exemplary conventional lightingconfiguration.

FIG. 5B illustrates a side view of a second exemplary conventionallighting configuration.

FIG. 6 illustrates a side view of an exemplary lighting configurationusing older technology LED.

FIG. 7 illustrates a side view of an exemplary lighting configuration inaccordance with the principles of the invention.

FIG. 8 illustrates an exploded perspective rear view of the lightassembly shown in FIG. 1 .

FIGS. 9A-9C illustrate cross-sectional views of exemplary embodiments ofthe invention showing the retaining of a dome lens in accordance withthe principles of the invention.

FIG. 10A illustrates a cross-sectional view of an exemplary lightingelement in accordance with the principles of the invention.

FIG. 10B illustrates an expanded view of the area indicated as A in FIG.10A, in accordance with a first aspect of the invention.

FIG. 10C illustrates an expanded view of the area indicated as A in FIG.10A, in accordance with a second aspect of the invention.

FIG. 11A illustrates an exploded perspective view of an exemplaryPCB/LED assembly and threaded section in accordance with the principlesof the invention.

FIG. 11B illustrates a perspective view of the exemplary PCB/LEDassembly shown in FIG. 11A.

FIG. 11C illustrates a cross-section view of another aspect of alighting element in accordance with the principles of the invention.

FIG. 12A illustrates an exploded perspective view of an exemplaryPCB/LED assembly in accordance with a second aspect of the invention.

FIG. 12B illustrates a perspective assembled view of the exemplaryPCB/LED assembly shown in FIG. 12A.

FIG. 12C illustrates a cross-sectional view of the exemplary PCB/LEDassembly shown in FIG. 12B.

FIG. 13 illustrates an exemplary lighting unit including a lightassembly shown in FIG. 8 in accordance with the principles of theinvention.

FIG. 14 illustrates an exemplary eyewear configuration incorporating thelighting unit shown in FIG. 13 .

FIG. 15 illustrates an exemplary light projection in accordance with theprinciples of the invention.

FIG. 16 illustrates a cross-sectional view of a second exemplaryembodiment of the invention in accordance with the principles of theinvention.

FIG. 17 illustrates a cross-sectional view of a third exemplaryembodiment of the invention in accordance with the principles of theinvention.

FIG. 18 illustrates a cross-sectional view of a second exemplary PCB/LEDassembly in accordance with the principles of the invention.

It is to be understood that the figures and descriptions of the presentinvention described herein have been simplified to illustrate theelements that are relevant for a clear understanding of the presentinvention, while eliminating, for purposes of clarity many otherelements. However, because these omitted elements are well-known in theart, and because they do not facilitate a better understanding of thepresent invention, a discussion of such elements are not providedherein. The disclosure herein is directed to also variations andmodifications known or should be known to those skilled in the art froma reading the disclosure presented herein.

DETAILED DESCRIPTION

FIG. 1 illustrates an exploded perspective view of a light assembly 100in accordance with the principles of the invention.

The light assembly 100 comprises a housing 110 including therein alighting element 112 comprising a Light Emitting Diode (LED) 115substantially centered on a printed circuit board (not shown) that isretained within the housing 110. The printed circuit board (PCB)includes electrical/electronic circuitry that controls the operation ofLED 115 (e.g., turn on/off). An aperture holder (or plate) 120 andaperture 130, including substantially centered openings 125, 135respectfully, are further illustrated. Aperture holder 120 and aperture130, as will be discussed, provide for reduction of stray lightemanating from LED 115.

Although described herein is the term “LED”, it would be under stoodthat the term “LED,” may comprise a plurality of LEDs arranged in apattern (e.g., a matrix). Hence, the use of the term “LED,” refers to atleast one LED.

Further illustrated is a dome lens 140 that is substantially centeredover LED 115. As will be discussed, LED 115 is positioned within or at afocal point of dome lens 140.

A lens assembly 150 is further illustrated and is attachable to housing110 to retain the lighting element 112 within the housing 110.

Housing 110, further includes an internal screw thread 117, which matesto a corresponding screw thread 151 on lens assembly 150 so that housing110 and lens assembly are rendered as a single unit (i.e., lightassembly 100).

Although a screw thread is illustrated, it would be recognized thathousing 110 and lens assembly 150 may be joined by other means. Forexample, housing 110 and lens assembly 150 may be joined together usinga bayonet connection, a snap-fit connection, a form fit connection andother similar connections, without altering the scope of the invention.

Further shown, on lens assembly 150, are grooves 154 that substantiallycircumvent lens assembly 150. Grooves 154, which is an optional featureof lens assembly 150, provide for an increased surface area todistribute heat generated within lighting element 100, as will beexplained.

FIG. 2 illustrates a cross-sectional view of the exemplary lightassembly 100 shown in FIG. 1 in accordance with the principles of theinvention.

In this exemplary embodiment, the lens assembly 150, which issubstantially cylindrical comprises a first section 226 (i.e., a lenssection) and a concentrically mated second section 225 (i.e., anattachment section) integrally incorporated onto first section 226.First section 226 houses at least one lens (of which two are shown 152,153). Second section 225 includes threads 151, formed on andcircumscribing the outer surface of attachment section 225. Thread 151provides, in this illustrative example, a means for attaching the lensassembly 150 to the housing 110.

In the exemplary embodiment shown, lens assembly 150 is mated to housing110 by engaging screw thread 151 on attachment section 225 with internalscrew thread 117 of housing 110, wherein screw thread 151 and screwthread 117 are of a matching thread characteristic (i.e., threadcount/inch, pitch).

Although screw thread 151 is shown as an external thread and screwthread 117 as an internal thread, it would be recognized that the screwthread 151 may be an internal screw thread while screw thread 117 may bean external screw thread, without altering the scope of the invention.

Similarly, the use of a bayonet connection, a snap-fit connection or aform-fit connection may be utilized to attach lens assembly 150 tohousing 110 without altering the scope of the invention. Bayonet,snap-fit and form-fit connections are well-known in the art and thosewith knowledge in the art would recognize and understand other means foradapting the exemplary threaded connection, discussed herein, withanother type of connection, based on a reading of the teachings providedherein.

For example, regarding a bayonet connection, it would be understood thatthe attachment section 225 may comprise a plurality of nipples or tabsextending from an outer surface of attachment section 225. The nipplesmay engage a plurality of “L-shaped” grooves or depressions within thehousing 110, wherein after a nipple engages a corresponding first leg ofthe “L-shaped” groove, a twist of lens assembly 150 forces the nipple toengage a second leg of the corresponding “L-shaped” groove. Thus, thelens assembly is “locked” in place with (i.e., attached to) housing 110.

While both a thread attachment and a “bayonet” attachment are disclosed,it would be recognized by those skilled in the art that other types ofattachment mechanisms may be incorporated into the subject matterdisclosed; such other type of attachment mechanisms have beencontemplated and considered to be within the scope of the inventionclaimed.

Further shown in FIG. 2 is at least one biconvex lens 152 within lensassembly 150. In the exemplary embodiment illustrated, two lenses 152and 153 are shown. The at least one biconvex lens(es) 152 (153) providea means for focusing light provided by LED 115 onto a surface at a knowndistance from the at least one lens 152 (153). It would be understood bythose skilled in the art that the number of lens may be increased ordecreased without altering the scope of the invention.

Although a biconvex lens is shown it would be recognized that the lensmay be one or more of a plano convex lens, a meniscus lens (which isconvex and slightly concave) or an aspheric lens without altering thescope of the invention claimed. The lens(es) 152 (153) may be composedof glass or plastic without altering the scope of the invention claimed.

Further illustrated is lighting element 112 comprising printed circuitboard (PCB) 210, LED 115, electrically connected to, and positioned onPCB 210. LED 115 is positioned on PCB 210 along an optical axissubstantially centered with the biconvex lens(es) 152 (153), when lensassembly 150 is joined to housing 110. PCB 210 provides for control of acurrent, provided by a voltage or power source (not shown), that may beapplied to LED 115. The voltage applied to LED 115, through PCB 210,may, for example, be provided by a battery (DC voltage) or a low-voltagealternating current (AC) that is subsequently rectified to provide arectified DC voltage at the input of LED 115. The source(s) of voltage(i.e., the battery or the rectified AC/DC voltage) are not shown.However, such sources are well-known in the art and their structure(s)and/or operation are known to those skilled in the art and need not bediscussed herein.

PCB 210 may further include a switch (not shown) that may be used tocontrol a flow of electrical energy (i.e., voltage/current) to LED 115.For example, in a first position, the switch may prevent a voltage frombeing applied to LED 115; whereas in a second position, the switch maybe set to allow a voltage to be applied to the LED 115. The switch maybe an electronic switch (e.g., diode, transistor) or a mechanicalswitch. Control of the switch may be performed in response to amechanical input or an electronic input.

In another aspect of the invention, PCB 210 may include a currentregulator circuit (not shown), wherein voltage applied to LED 115 issubstantially constant (i.e., 3.7 volts) and the current to LED 115 isvaried. The current regulator circuit may include components that aredesigned to limit or vary (i.e., increase or decrease) the currentapplied to LED 115. In one aspect of the invention, the currentregulator circuit may set the current to one of a plurality of fixedvalues, such that the intensity of light outputted by LED 115 is changedbased on which of the plurality of fixed values is applied to LED 115.In another aspect of the invention, the current regulator circuit mayincrease (or decrease) the current applied to LED 115 over a fixedperiod of time. In another aspect of the invention, the currentregulator circuit may provide a switched current to LED 115. That is,the current may be alternatively applied to and removed from LED 115.The alternating application/removal of the current to/from LED 115causes LED 115 to be turned on/turned off, which due to the persistenceof the human eye is not noticed by the user. In this case, the abilityof the current regulator circuit to limit the duration of current to LED115 may increase the duration of the voltage source (e.g., a battery) asLED 115 is not continuously drawing energy from the source. As would beunderstood, the PCB 210 may further include a voltage regulator circuitthat provides a substantially constant and/or consistent voltage to LED115.

Further illustrated is dome lens 140 substantially proximate to andcentered with respect to LED 115. Dome lens 140 provides for amagnification of the light outputted by LED 115. The degree ofmagnification provided by dome lens 140 is based at least on thecurvature of dome lens 140 and the index of refraction of the materialselected for dome lens 140.

Further shown, on lens assembly 150 is rear surface 215 (i.e., a closedsurface) of attachment section 225 (see FIG. 8 ). Rear surface 215,which is representative of a retention means, includes a retainer (i.e.,an opening (or passthrough) 220 (see FIG. 2 ). Opening 220, which passesfrom a first (outer) surface 217 of retainer 215 to a second (inner)surface 219 of retainer, is substantially centered within retainer 215,and provides a means of centering and retaining dome lens 140 onto (orin close proximity to) LED 115, without the use of an adhesive orsimilar materials.

In accordance with the principles of the invention, without the use ofany glue or adhesive to retain dome lens 140 onto LED 115, the problemsof out-gassing and fogging are removed. That is, as is known in the art,the use a glue or adhesive and a retaining ring to retain a lens onto anLED is problematic as the heat generated by the LED and electroniccomponent on PCB 210 heats the glue or adhesive. The heated glue oradhesive then generates gases that fog the surface of the lens. In theillustrated embodiment shown in FIG. 2 , outgassing caused by a heatedglue or adhesive will not fog the inner facing surface of lens 153.

In accordance with the principles of the invention, opening 220 withinrear surface (retention means) 215 is formed such that the edges(surfaces) of opening 220 substantially match, or conform to, a radiusof curvature of lens 140. As lens assembly 150 is attached to housing110 (e.g., threads 117 engaging threads 151), dome lens 140 issubstantially self-centered within opening 220 and on (or in closeproximity to) LED 115, without any use of adhesive or glue.

Although the edges (surface) of opening 220, within retention means 215,are shaped to engage or contact a radius of the lens 140, it would berecognized that the edges of opening 220 may be machined to tangentially(i.e., a straight line) engage or contact the radius of curvature of thelens 140. Alternatively, the edges of opening 220 may be machined topartially conform to the shape of dome lens 140.

In a fully or partially conformal fitting, the surface (edges) ofopening 220 substantially match a radius of curvature of lens 140. Aconformal shaping of the surface of opening 220 is determined based onthe characteristics of dome lens 140. As would be recognized, theconformal shape of surface of opening 220 may fully match the radius ofcurvature of lens 140 or may match only a portion of the lens 140. Inone aspect of the invention, a thickness of retainer 215 may determinean amount of contact of a conformally shaped surface of opening 220 as athicker surface of retainer 215 allows for a more conformal shaping ofthe surface or edges of opening 220.

In accordance with another aspect of the invention, in a tangentialfitting (i.e., the edges (surface) of opening 220) may be chamfered,such that the surfaces of opening 220 are determined by the degree ofchamfer desired. As would be recognized, a thickness of retainer 215 maydetermine a chamfer angle, which allows for the edges or surface ofopening 220 to sufficiently contact dome lens 140.

In one aspect of the invention, the attachment section 225 (includingthreads 151) may be constructed of a heat transferrable medium to drawheat generated by the electronic components on PCB 210 away. Forexample, attachment section 225 may be constructed from at least one ofa copper, a tellurium, a copper tellurium alloy, an aluminum, or othersimilar type of heat conductive materials and alloys. Similarly, lenssection 226 may be constructed of a similar heat transferrable medium(e.g., aluminum, copper, tellurium, copper tellurium alloy, etc.). Inone embodiment, aluminum may be selected as a suitable material for lensassembly 150 (i.e., lens section 226, attachment section 225) asaluminum is light weight and a good heat conductor. However, othersuitable heat transfer mediums may be utilized without altering thescope of the invention (e.g., copper, tellurium, copper tellurium alloy,etc.). In accordance with the principles of the invention, attachmentsection 225 (including retention means 215) and lens section 226 may beconstructed from a single heat conductive material such that attachmentsection 225 (including retainer 215) and lens assembly 225 are anintegral piece. Alternatively, retention means 215, attachment section225 and lens section 226 may be constructed of different materials andthen joined together, permanently, to each other. Alternatively,retention means 215, attachment section 225 and lens section 226 may beof a same or of different heat transferable materials which may beremovable joined together.

In accordance with the principles of the invention, heat generated byLED 115/electronic components on PCB 210 may be transferred, through theengagement of the attachment section 225 (i.e., a coupler) to lenssection 226, wherein the heat generated by PCB 210/LED 115 may bedispersed into the surrounding environment.

As is further shown, lens section 226 of lens assembly 150 includes aplurality of grooves (i.e., deformations) 154 (or a single groovediagonally circumscribing housing 150), that extend circumferentiallyaround lens section 226. The incorporation of groove(s) 154 into lenssection 226 (i.e., lens assembly 150) is advantageous as it provides foran increased surface area, from which heat may be dispersed.

Although, FIG. 2 illustrates a plurality of grooves 154 within lensassembly 150 (or a single groove circumferentially around lens assembly150), it would be recognized that lens assembly 150 may include aplurality of protrusions, extensions, bumps or ridges (or a singleprotrusion diagonally circumscribing lens assembly 150) (not shown) thatextend from an outer surface of lens assembly 150. The (not shown)protrusions on lens assembly 150 also increase the surface area of lensassembly 150 to increase the efficiency of dispersing the generated heatinto the surrounding environment. In addition, grooves 154 (orprotrusions) may be spirally positioned (i.e., one continuous groove orprotrusion on the outer surface), concentrically positioned (i.e., aplurality of circular grooves or protrusions) and/or longitudinallypositioned (a plurality of grooves or protrusions longitudinallypositioned on the outer surface), without altering the scope of theinvention. As would be recognized grooves (or protrusions) 154 mayrepresent deformations within (or on) an outer surface of lens assembly150.

In another aspect of the invention, PCB 210 may be in contact withattachment section 225, such that the heat generated by the LED 115 andthe electronic components on PCB 210 may be transferred to lens assembly150. For example, a heat conductive material (e.g., copper wire orcopper ring) may contain PCB 210, therein, wherein the copper wire orcopper ring contacts the attachment section 225 so as to transfer theheat of LED 115/PCB 210 through the copper ring element 305 to lensassembly 150.

In accordance with the principles of the invention, the operation oflight assembly 100 remains consistent as the heat generated by the LED115 is efficiently removed from the interior of the light assembly 100.

FIG. 3A illustrates a front view an exemplary embodiment of a ringelement 305 showing PCB 210 contained therein. Further illustrated isLED 115 substantially centered on PCB 210. Electrical connections 310 aand 310 b provide electrical energy (voltage/current) to LED 115.Further illustrated is border 114 surrounding LED 115. Border 114represents an area in which the LED 115 outputs a light that is notsubstantially white.

That is, white LEDs are manufactured using a combination of a blue LEDand a yellow phosphor. White light is perceived when blue light from theLED is mixed with a yellow light that is emitted from the phosphor. Inthe illustrated embodiment shown, the blue LED portion of LED 115 issubstantially centered in LED 115, and is in contact with a phosphoruslayer (represented as border 114). The mixture of the blue LED lightwith the yellow light of the phosphorus layer causes a white light to bevisible.

FIG. 3B illustrates a second aspect of the exemplary front view shown inFIG. 3A, wherein aperture holder 120 is positioned on PCB 210. Apertureholder or plate 120 includes a first groove (i.e., depression) 320extending a length (e.g., diameter) of aperture holder 120. Furthershown is second groove (i.e., depression) 330 extending substantiallythe length of aperture holder and oriented substantially perpendicularto first groove 320.

Returning to FIG. 1 , FIG. 1 further illustrates the incorporation offirst groove 320 and second groove 330 within aperture holder 120.Further shown is opening 125 of aperture holder 120 at the intersectionof the first groove 320 and second groove 330. Opening 125 is centeredwithin aperture holder 120 and sized to enable at least the blue LEDportion of LED 115 to be viewed therethrough.

FIG. 3C illustrates a third aspect of the exemplary front view shown inFIGS. 3A, 3B, wherein aperture 130 includes a first leg 350 and a secondleg 360 substantially perpendicular to first leg 350. An opening 135 inaperture 130 is positioned at an intersection of the first leg 350 andthe second leg 360. As shown, first leg 350 is positioned within firstgroove 320 and second leg 360 is positioned within second groove 330 ofaperture holder 120. Further illustrated is opening 135 centered overLED 115. Opening 135 is sized such that only a center section (i.e.,blue LED portion) of LED 115 is viewable through opening 135. Apertureholder 120 and aperture 130 limit stray light generated by thephosphorous layer (i.e., border 114) from being viewable.

First groove 320 and second groove 330 of aperture holder or plate 120allow for the proper positioning and alignment of aperture 130 onto orin close proximity to LED 115. Although grooves 320 and 330 on apertureholder 120 are illustrated and discussed, in an alternative embodimentgrooves 320 and 330 may be holes within aperture holder 120 into whichtabs of aperture 130 may be inserted in order to align aperture 130 withaperture holder 120.

FIG. 3D illustrates a back view of PCB 210 showing the substrate formingPCB 210 and exemplary components and electrical connections used incontrolling the application (or the removal) of a voltage and current toLED 115. Electrical components on PCB 210 may comprise one or morepassive devices, such as resistors, capacitors and inductors and one ormore active devices, such as transistors and diodes. These componentsmay be joined together to form a controller that is usable incontrolling the operation of the LED 115. In another aspect of theinvention, the components may include a microprocessor, amicrocontroller or a special purpose integrated circuit (e.g.,Application Specific Integrated Circuit) that includes processing tocontrol the application, or removal, of a voltage/current from LED 115.

In addition, components suitable for operation with the transmission andreception of signals for controlling the application of voltage/currentto LED 115 may be incorporated on PCB 210. For example, componentsassociated with an IR (infra-red) transmitter and receiver may beincorporated onto PCB 210. IR components may, for example, be used totransmit an IR signal, which when a reflection of such signal isdetected by the IR receiver, cause the generation of a signal that maybe provided to the controller to control the application of avoltage/current to LED 115 (i.e., turn on and/or turn off). Similarly,the signal provided to the controller associated with the detected IRsignal may be used to alter (increase/decrease) the voltage/currentapplied to LED 115. Although IR signal is discussed it would berecognized that the transmitter and receiver may be associated with RF(radio frequency) and/or audio (ultra-sonic waves). U.S. Pat. No.8,215,791, which is assigned to the Assignee of the instant application,the contents of which are incorporated by reference, herein, disclosesoperation of such IR signal control.

In another aspect of the invention, PCB 210 may include components thatare associated with voice recognition, wherein a verbal command such as“turn-on”, “turn-off”, “Raise, “Lower,” may provide signals to thecontroller such that a corresponding alteration of the voltage/currentto LED 115 may be effected.

FIG. 4A illustrates a cross-sectional view of an exemplary dome lens 140in accordance with the principles of the invention. In this illustrateexample, the dome lens 140 is represented as being of substantially of asemi-spherical shape. Dome lens 140 may be constructed or fabricated,for example, by removing a portion of a spherical, substantially clearmaterial, along a diameter of the sphere. As would be known in the art,the sphere diameter divides the sphere into two equal halves; ahemispherical shape, which in a cross-sectional view is represented by asemi-circular shape. In a more general sense, dome lens 140 may beconstructed or fabricated by removing a portion of the sphericalmaterial along a chord of the spherical material.

As would be known in the art, the shape of dome lens 140 and the indexof refraction of the material from which the sphere is createddetermines a degree of magnification of dome lens 140. In thisillustrated cross-sectional view of dome lens 140, dome lens 140 is of asemi-circular shape having a radius of 2 mm (millimeters) as theoriginal spherical shape has a diameter of 4 mm.

FIG. 4B illustrates exemplary characteristics of the spherical shape 410used to form dome lens 140 shown in FIG. 4A. In this illustratedembodiment, dome lens 140 is constructed or manufactured by dividing ordissecting sphere along its diameter 415. By dividing sphere 410 alongits diameter, two equal (i.e., hemispheric or semi-spherical) elements420, 425 are formed. In this illustrated embodiment, dome lens 140 isrepresented by one of the two hemispheric elements.

In this exemplary dome lens 140 construction, measures 435, 440, 445,extending from a central point of the spherical material are equal inboth the horizontal and in the vertical (i.e., perpendicular to thehorizontal) direction.

FIG. 4C illustrates a cross-sectional view of a second exemplary domelens 140 having a 4 mm diameter which is constructed or fabricated byremoving or dividing the spherical element along a chord different thanthe diameter. In this illustrated example of a 4 mm sphere, the measureextending substantially perpendicular to the horizontal axis is smallerthan those measures along the horizontal axis.

FIG. 4D illustrates a cross-section of a third exemplary dome lens 140in accordance with the principles of the invention.

In accordance with the principles of the invention, an exemplary domelens 140 may be constructing from a 4 mm sphere (i.e., radius 2 mm), bytrimming (cutting, shaving) along choral axis 440, such that a length ofthe dome lens 140, which is measured from the choral axis 440 to an edgeof the dome lens 140 is greater than the radius (i.e., 2 mm) of sphere.

FIG. 4E illustrates an exemplary characteristics of dome lens 140 shownin FIG. 4D.

In this exemplary embodiment, a spherical element is machined alongchord 450 such that dome lens 140 possesses an equal length elementalong the chordal (horizontal) direction (R1), while the length (R2), inthe substantially perpendicular direction, is greater than that of R1.

As would been known to those skilled in the field of mathematics, aspherical cap, a spherical dome or a spherical segment may be determinedor formed from a portion of sphere cut off by a chordal plane. When thechordal plane passes though the center of the sphere, so that the heightof the cap is equal to the radius of the sphere, the spherical cap isreferred to as a hemisphere. However, the cap (i.e., dome lens 140) maybe of another shape, as shown in FIGS. 4C and 4D, by passing a chordalplane through a different section of the sphere that is not the diameterof the sphere.

In accordance with the principles of the invention, the increased lengthof the dome lens 140 in a substantially perpendicular direction (i.e.,vertical) from the chordal plane increases the magnification capabilityof the lens element. The increased magnification provides for a greaterprojection of light.

Using well known geometric principles, the cord lengths (R1, R2) shownin FIG. 4E, for example, may be determined from conventionalmathematical formulas and need not be discussed herein.

FIGS. 4A-4E illustrate exemplary dome lens 140 configurations suitablefor use in lighting element 112 discussed herein. However, it would berecognized by those of ordinary skill in the art, that variousmodifications and changes to the construction of a dome lens 140 can bemade without departing from the scope of the invention as set forth inthe claims. Such modifications and changes have been contemplated andare considered to be within the scope of the invention claimed. Forexample, while it is disclosed that dome lens 140 may be fabricated froma spherical element, if would be recognized that dome lens 140 may befabricated as a desired shape by successive depositing of layers ofoptically clear materials onto an optically clear substrate, withoutaltering the scope of the invention.

FIG. 5A illustrates an exemplary conventional LED lighting elementconfiguration. In this exemplary configuration, LED 115′ (whichrepresents a typical conventional (older technology) LED), is positionedon PCB 210 and is positioned behind lens 152 such that LED 115′ ispositioned at a focal point 510 of lens 152. LED 115′ is covered by alens, which, as has been discussed, is held in place using a glue oradhesive.

The conventional LED 115′ illustrated is of a size of 3 mm×3 mm (i.e., 9square mm), which provides a desired illumination output for a knowncurrent input.

FIG. 5B illustrates a second exemplary LED configuration, similar tothat disclosed in U.S. Pat. Nos. 7,690,806 and 8,215,791, which areassigned to the Assignee of the instant application, and whose contentsare incorporated by reference, herein.

In this second exemplary configuration, a conventional LED 115′ ispositioned behind lens 152 such that LED 115′ is positioned within thefocal point 510 of lens 152. In this second exemplary configuration, thelight generated by LED 115′ is focused (i.e., de-focused) to improve thepresentation of the light projected onto a surface (not shown).

FIG. 6 illustrates an exemplary light element configuration similar tothat shown in FIG. 5B using contemporary (i.e., current technology) LED115. As the LED 115 is smaller (i.e., 1 mm×1 mm) than a typicalconventional LED 115′ (FIG. 5A), the amount of light that passes throughlens 152 is less due to the decreased LED die size.

FIG. 7 illustrates an exemplary lighting element configuration inaccordance with the principles of the invention.

As shown, LED 115 is positioned on or in close proximity to dome lens140 and is further positioned within a focal length 510 of lens 152 andwithin a focal length 720 of dome lens 140. Although FIG. 7 illustratesLED 115 being positioned within the focal length 720 of dome lens 140,it would be appreciated that LED 115 may be positioned at the focalelement 720 of dome lens 140, without altering the scope of theinvention.

In this illustrated embodiment of the invention, the light generated byLED 115 is first focused (or de-focused) by dome lens 140 to produce alight having a smaller (i.e., narrower angle) distribution such that agreater amount of light from LED 115 is directed toward lens 152. Thelight directed toward lens 152 is then projected on to a surface (notshown) at a known distance from lens 152 to provide a brighter andsubstantially uniform light distribution pattern on the surface.

In an alternative embodiment, and similar to that shown in FIG. 1 , anaperture holder 120 and aperture 130, which is held in place by apertureholder 120 are included. Aperture 130 includes an opening 135, throughwhich the light generated by LED 115, passes. The use of aperture 130 isadvantageous as it limits the light generated by the phosphorous portion(i.e., border 114) of LED 115. Aperture 130, thus, defines that lightprojected onto a surface at a known distance from lens 152.

FIG. 8 illustrates an exploded rear perspective view of the lightassembly 100 in accordance with one embodiment of the invention.

In this illustrated aspect of the invention, which is similar to thatshown in FIG. 1 , threads 151 are formed on the outer surface ofattachment section 225. As previously discussed, housing 110 engageslens assembly 150 by engaging threads 151 to thread 117 (not shown) inhousing 110. Further illustrated are aperture holder 120, aperture 130and dome lens 140, as previously discussed. Also illustrated is opening220 formed within retention means 215 of the attachment section 225.Surface 810, formed by the opening 220 provides a means for retainingand centering dome lens 140.

To provide for a self-centering of dome lens 140 within opening 220,surface 810 is formed to be substantially comparable (e.g., conformal)to the shape of dome lens 140.

In accordance with one aspect of the invention, the surface (i.e.,ridge, edge) 810 may be formed to match the curvature curved shape ofdome lens 140. In accordance with another aspect of the invention,surface (i.e., ridge) 810 may be chamfered (i.e., angled) such that theridge 810 tangentially contacts lens 140.

FIG. 9A, FIG. 9B and FIG. 9C illustrate exemplary configurations ofsurface 810 in accordance with the principles of the invention.

FIG. 9A illustrates a cross-sectional view of an exemplary engagement ofsurface 810 (labelled 810 a) formed to match a radius of curvature(conformal fit) of dome lens 140.

FIG. 9B illustrates a cross-sectional view of an exemplary engagement ofsurface 810 (labelled 810 b) to dome lens 140, wherein surface 810 ischamfered, at a first angle, to tangentially contact lens 140.

FIG. 9C illustrates a cross-sectional view of a second exemplaryengagement of surface 810 (labelled 810 c) to dome lens 140, whereinsurface 810 is chamfered, at a second angle, to tangentially contactdomed lens 140. As would be appreciated, the angle of the chamfer andthe radius of curvature of the dome lens 140 determines an amount ofcontact surface 810 has with domed lens 140.

As would be recognized, the angle of chamfer of surface 810 determines apoint (or points) of contact of surface 810 with dome lens 140. As wouldbe further recognized, the angle of chamfer determines a size of opening220 through which dome lens 140 protrudes. As would be furtherrecognized, the angle of chamfer (or the radius of curvature) depends ona size of the dome lens 140 (i.e., the radius of curvature). Hence, theangle of chamfer or the radius of curvature of surface 810 may bealtered and adapted to comport with the radius of curvature of theselected domed lens 140.

Returning to FIG. 8 , further illustrated is an anti-reflective coating875 on a surface (i.e., rear and/or dome) of dome lens 140.Anti-reflective coating 875 is advantageous as it reduces reflections ofthe light generated by LED 115 from the back surface of dome lens 140.

FIG. 10A illustrates a cross-sectional view of light assembly 100,similar to that shown and described with regard to FIG. 2 . In thisillustrated view, an enlargement (i.e., a circled area, labelled “A”),illustrates the retention of dome lens 140 by surface 810 in opening 220of retention means 215.

FIG. 10B illustrates an expanded view of the area labelled “A” in FIG.10A showing the fit, connection or contact between the dome lens 140 andsurface 810. In this illustrated exemplary embodiment, the surface 810,which contacts dome lens 140, is represented as a substantiallyconformal fit, wherein surface 810 follows all or a portion of thecurvature of lens 140.

FIG. 10C illustrated an expanded view of the area labelled “A” in FIG.10A, wherein the surface 810 is configured to fully conform to thecurvature of lens 140.

As would be recognized, the degree of conformity of surface 810 to thecurvature of lens 140 is determined based on the degree to which suchconformity is desired, the ability of manufacturing machines to machineor form surface 810 and a thickness of rear surface 215.

FIG. 11A illustrates an exploded perspective view of PCB 210 and ahousing attachment section 1130, in accordance with the principles ofthe invention. In this illustrated embodiment, PCB 210 is containedwithin a ring or holder 1110, which is composed of a heat transferrablematerial (e.g., copper, aluminum, etc.). Ring or holder 1110 iscomparable to holder 305 shown in FIG. 3A.

As discussed, the heat generated by components positioned on PCB 210/LED115 may be transferred through the ring or holder 1110 to the lensassembly 150 to draw heat generated by the LED/PCB components away fromthe electronic components.

Although the term “ring” is used to describe element 1110, it would berecognized that element 1110 may be constructed as a plate of a heattransferrable material into which a depression or cavity is formed. PCB210 may then be placed and retained within the depression or cavity ofthe plate. Or PCB 210 may simply be placed on a plate of heattransferrable material.

In the exemplary embodiment shown, on surface of ring 1110 are aplurality of alignment holes or depressions 1120 that project into asurface of ring 1110. Further shown is housing attachment section 1130,including a plurality of pegs 1135, extending substantiallyperpendicular to the attachment section 1130 and an internal screwthread. Internal screw thread, may, in one aspect of the inventioncorrespond to internal screw thread 117, shown in FIG. 1 .

In this illustrated embodiment, when housing attachment section 1130 isjoined with ring 1110 (see FIG. 11B), pegs 1135 are inserted intocorresponding holes (depressions) 1120. Both ring 1110 and housingattachment section 1130 are constructed from a heat conductive medium,such that the heat of PCB 210/LED 115, caused by the operation of theelectronic components thereon, is transferred to the housing section1130. As previously discussed, this generated heat is subsequentlytransferred to the lens assembly 150 (not shown) by the attachment ofhousing 110 to lens assembly 150. Hence, the joined ring 1110 andhousing attachment 1130 operate as a heatsink to remove heat generatedby LED 115/electronic components on PCB 210. Attachment section 1130 maythen be solder connected to ring 1110 to provide for better heattransfer between the two elements.

Although ring 1110 and section 1130 are shown attached using alignmentpegs, it would be recognized that the ring 1110 and attachment section1130 may be attached through a screw thread attachment, a bayonet fitattachment, a snap fit attachment, a form fit attachment, a butt fitattachment, etc., without altering the scope of the invention. Screwthread, bayonet, snap-fit and butt fit attachment means have beenpreviously discussed and need not be discussed further herein.

FIG. 11C illustrates another aspect of the housing 110, shown in FIG. 1, wherein the ring element 1110 and attachment 1130 are containedtherein.

Further shown is lighting element 112 including PCB 210, and LED 115.Aperture holder 120 and aperture 130 are further illustrated.

In this illustrated case, ring 1110 and attachment section 1130 aresized to contact housing 110. Screw thread 117 is contained within theattachment section 1130 and operates in a manner similar to thatdiscussed with regard to FIGS. 1 and 2 .

As previously discussed, PCB 210 within ring 1110 (see FIG. 3A, FIG.11A) provides for the transfer of heat generated by the component on PCB210 and/or LED 115 away from PCB 210 and LED 115. In this illustratedcase, the heat is transferred to housing 110.

It would be appreciated that attachment means 225, when connected tohousing 110, through screw thread 117, provides further surface area towhich heat may be transferred away from PCB 210 and LED 115 through lensassembly 150.

FIG. 12A illustrates an exploded perspective view of the positioning ofthe aperture holder 120 and aperture 130 onto PCB 210. As previouslydiscussed, aperture holder 120 includes opening 125, which is sized toallow LED 115 to protrude therethrough such that a surface of LED 115 issubstantially flush with a top surface of aperture holder 120. Opening125 is sized and shaped to tightly accommodate LED 115, such that straylight from LED 115 is prevented from passing through. Aperture holder120 furthermore centers aperture 130 on, or in close proximity to, LED115 as previously discussed. Opening 135 in aperture 130 is sized toprevent stray light from LED 115 from passing through.

FIG. 12B illustrates a perspective view of an exemplary lighting element112.

In this illustrated exemplary lighting element, aperture holder 120 isgrooved or slotted to retain aperture 130 in place, wherein aperture 130is constructed to match the grooves or slots within aperture holder 120.Although not shown, aperture 130 may include a plurality of tabs thatengage a corresponding groove in aperture holder 120. The tabs onaperture 130 provide for an alignment of the aperture with the apertureholder 130 and LED 115.

FIG. 12C illustrates a cross-sectional view of the assembled lightingelement shown in FIG. 12B.

In this illustrated lighting element 112, aperture holder or apertureplate 120 is positioned atop PCB 210, wherein a portion of LED 115, onPCB 210, passes through passthrough 125, as previously discussed.Aperture holder 120 partially blocks light generated by the phosphorussection (border 114) of LED 115 from being visible. Further shown isaperture 130, contained within grooves or slots 330 of aperture plate120. Aperture 130 includes passthrough 135, which allows light from LED115 to passthrough. As discussed, with regard to FIGS. 3A-3C,passthrough 125 in aperture holder 120 and passthrough 135 in aperture130 are sized to prevent stray light emitted from the phosphorus portion(block 114) of LED 115 to pass through. Thus, only a white light fromLED 115 is passed to dome lens 140. Although white LED light isdiscussed, it would be recognized that the principles presented hereinmay be applied to LED light of different colors, without altering thescope of the invention.

Further, shown in FIG. 12C, is dome lens 140 positioned on a surface ofaperture holder 120, as aperture 130 is contained entirely within groove330. In an alternate embodiment, dome lens 140 may similarly bepositioned on aperture 130 by sizing aperture 130 to be of a greaterdepth than groove 332 of aperture holder 120. In a further alternativeembodiment, dome lens 140 may be positioned directly on LED 115 with theappropriate sizing of passthrough 135 in aperture 120. Further shown isoptional anti-reflective coating 875. Anti-reflective coating 875 may beincluded on at least one of the rear surface of dome lens 140 and thedomed surface of dome lens 140.

Returning to FIG. 8 , incorporated onto a distal end of housing 110 isconnector 820. Connector 820 provides means for attaching light assembly100 onto a frame or eyewear (not shown). The frame may represent a meansfor retaining the light assembly to a person. The frame may be one of aneyewear, a headset, and a headband. Alternately, the frame may be a clipthat may be used to attach the light assembly 100 to one of a shirtpocket, a belt, and shirt collar. Alternatively, the connector 820 maybe used to position light assembly 100 in an overhead configuration orin a flashlight configuration.

In one aspect of the invention, connector 820 may include a slot 830that allows for the removable attachment of light assembly 100 to theframe (not shown). The slot 830 may, for example, be a T-slot connector,which attaches to a mating T-slot connector on the frame (not shown).

FIG. 13 illustrates an exemplary lighting unit 1300 incorporating thelight assembly 100 shown in FIG. 1 , for example.

In this exemplary lighting unit 1300, light assembly 100 is attachedthough a pivot attachment 1330 to a housing section 1340, which includesan IR transmitter/detector system 1320. The IR transmitter/detectorsystem may provide signals to the PCB 210 (not shown) of lightingelement 112 to control the illumination output of LED 115.

Further illustrated is a battery pod element 1310, which includes abattery therein. The battery provides power (voltage/current) to the LED115 of lighting element 112. The voltage/current provided by the batteryto the LED 115 is controlled by one or more switches on PCB 210.

Battery pod 1310 may be attached to the housing section 1340 by one of ascrew connection, a bayonet connection, a snap fit connection, etc.

Although the light assembly 100 is shown including a wireless orcordless operation of a switch to control a flow of electrical energy(i.e., power) to LED 115 (not shown), it would be recognized that lightassembly 100 may include a physical switch that controls the flow ofelectrical energy to LED 115. For example, the switch may be a toggleswitch that controls the application of power (i.e., voltage/current) toLED 115. Alternatively, the switch may be a capacitive touch switch thatprovides a signal to a switch that controls the application of power(i.e., voltage/current) to LED 115. For example, a capacitive touchswitch may be activated when the battery pod 1310 is contacted, whereina first touch may send a signal to the switch that allows power to beprovided to LED 115 and a second touch sends a signal to the switch toprevent power from being provided to LED 115.

FIG. 14 illustrates an exemplary eyewear 1400 incorporating the lightingunit 1300 shown in FIG. 13 . In this illustrative embodiment, lightingunit 1300 is attached, through connector 820, to eyewear 1400. Eyewear1400 includes frame 1405 and lens 1420 a (not shown) and 1420 b. Furtherillustrated is temple 1410 a that allows for the retention of eyewear1400 to a person. As previously discussed, eyewear 1400 includes aconnector 1430 matching the connector 820 to allow light unit 1300 to beremovably attached to the eyewear 1400.

Although FIG. 14 illustrates a conventional eyewear 1400 through whichlighting unit 1300 may be attached, it would be recognized that lightingunit 1300 may similarly be attachable to a headband, a headset, a shirtpocket, etc. Similarly, light assembly 100, and specifically thelighting element 112, may be incorporated into an overhead light, a desklamp, etc., wherein a plurality of lighting elements may be concurrentlyused to provide for a large-scale light output.

Table 1 tabulates exemplary experimental results obtained from thelighting element configuration 112 illustrated in FIG. 7 , in the lightassembly 100 shown in FIG. 1 , using the domed lens 140 of differentchordal dissections in accordance with the principles of the invention.

In this exemplary test configuration, a light is projected onto asurface approximately sixteen (16) inches away (i.e., a known distance)from projection lens 152. The dome lens 140 is constructed from anexemplary 4 mm diameter sphere of optically transparent material (e.g.,glass, crystal, optically clear plastic, etc.). A current applied to LED115 is set at 700 milliamperes (mA). As would be known in the art, thecurrent applied to LED 115 determines a light intensity produced by LED115.

The selection of 700 milliamps is made merely to obtain the tabulatedtest results shown herein and is not considered the only current levelthat may be applied to LED 115.

FIG. 15 illustrates an exemplary light pattern projected onto thesurface wherein the pattern is adjusted until a substantially squareshape is displayed. In accordance with principles of the test, adimension (D) of the projected square is set to be substantially thesame for each of the different levels of magnification of dome lens 140.

A level of intensity of the projected light is measured, infoot-candles, for each of the different levels of magnification of domelens 140 under the test conditions of the application of 700 ma ofcurrent, with a substantially same size projected light image (i.e.,measurement D).

The Dome Lens Size (i.e., length) is defined as the distance between thechordal axis and an edge of the spherical dome. For example, the DomeLens Size is represented by R, in FIG. 4B and R2 in FIG. 4E.

TABLE 1 Dome Lens Size (height) Lens Power Diagonal size (D) Intensity(mm) (diopters) (mm) (Foot-candles) 2.00 26.5 × 2 lens 45 6070 2.28 26.5× 2 lens 51 7500 2.41 21.5 × 2 lens 46 7000 2.50 21.5 × 2 lens 51 68002.70 21.5 × 2 lens 59 6500 3.25 26.5 × lens — —.

In accordance with the principles of the invention, a dome lens 140,constructed from an exemplary 4 mm sphere, having characteristics thatachieves a desired level of intensity and uniformity of lightdistribution over a desired size may be determined from the tabulatedresults.

Although Table 1 tabulates test results associated with a specific testcondition (e.g., 4 mm sphere, 700 milliamp current), it would beunderstood that the results presented herein are only representations ofthe operation of the invention. Other chordal selections and/or spheresizes and/or applied current values may be determined and have beencontemplated and are considered to be within the scope of the inventionclaimed.

FIG. 16 illustrates a lighting element in accordance with a secondexemplary embodiment of the invention claimed.

In this exemplary embodiment of light assembly 1600, which is similar tothe light assembly shown in FIG. 1 , including a housing 1610, intowhich is contained lighting element 112, including contained PCB 210,LED 115, aperture holder 120/aperture 130 and dome lens 140. Housing1610 includes an internal screw thread 1617, which is similar to screwthread 117 contained in housing 110 shown in FIG. 1 .

Further shown is lens assembly 1650 including lens 152, 153, which issimilar to lens assembly 150 shown in FIG. 1 . Further illustratedwithin lens assembly 1650 is internal screw thread 1654.

Further shown is coupler 1620, which includes a closed first end 1630,which is representative of retention means 215, and an open second end1640. Closed first end 1630, similar to retention means 215, includes anopening 220, and surface 810 in opening 220, similar to those elementsdisclosed and shown with regard to FIG. 8 and FIGS. 10A-10C.

Coupler 1620 further includes a screw thread 1651 shown on an externalsurface of coupler 1620. Screw thread 1651, similar to the screw threadconfiguration disclosed with regard to screw thread 115 matches screwthread 1617 on inner surface of housing 1610.

In one aspect of the invention, screw thread 1651 may be positionedalong an entire external surface of coupler 1620. In accordance with oneaspect of the invention, screw threads 1651, 1654 and 1617 may becomparable with regard to thread count/inch and pitch. In another aspectof the invention, screw thread 1651 may be positioned along a portion ofthe external surface of coupler 1620, wherein screw threads 1654 and1617 may be of a different thread count/inch and pitch and screw thread1651 on coupler 1620 is formed to engage screw threads 1654 on one endand screw threads 1617 on a second end.

As previously discussed, surface 810, within retention means 215, isshaped (either conformally or tangentially) to contact a surface of domelens 140 to retain dome lens 140 substantially in contact with (or inclose proximity to) LED 115, without any adhesive materials.

In accordance with the principles of the invention, coupler 1620 may bescrewed to housing 1610 through the connection of screw thread 1617 withscrew thread 1615 to retain dome lens 140 in place, as previouslydiscussed. Lens assembly 1650 may then be attached to coupler 1620 bythe connection between screw thread 1651 and screw thread 1654.

Operation of the illustrated second embodiment of the light assembly1600 is similar to that discussed with regard to FIG. 1 , as heatgenerated by PCB 210/LED 115 may be channeled or drawn to theenvironment through the heat transfer from PCB 210 through coupler 1620and lens assembly 1650.

Although FIGS. 1 and 16 illustrate coupler 1620 including retentionmeans 215, including a screw thread for attaching the lens assembly 150(or 1650) to housing 110 (1610), it would be recognized that attachmentmeans 225 (coupler 1620) may include a bayonet connection, a snap fitconnection, or a butt fit connection without altering the scope of theinvention.

The illustrated second embodiment of the invention shown in FIG. 16allows for the changing of lens assembly 1650 (and the projection lens152, 153) without causing any change in the position of dome lens 140held in place by surface 810.

FIG. 17 illustrates a cross-sectional view of a third exemplaryembodiment of the invention in accordance with the principles of theinvention.

FIG. 17 , similar to FIG. 2 , illustrates a housing 110, a lightingelement 112 and lens housing 1750 containing at least one lens 152, 153.As housing 110 and lighting element 112 are comparable to these elementsdiscussed with regard to FIG. 2 , a detailed discussion of theseelements need not be repeated.

In this exemplary embodiment, lens housing 1750 is comparable to lenshousing 150, discussed with regard to FIG. 2 , in that lens housing 1750includes a lens section 226 and an attachment section 1725. Attachmentsection 1725 further includes threads 151 b, similar to threads 151shown in FIG. 2 . Threads 151 b operate in a manner similar to threads151, of FIG. 2 , in attaching lens assembly 1750 to housing 110.

In this illustrated third embodiment, attachment section 1725 of lensassembly 1750 is open ended, wherein light generated from LED 115 passesthrough to at least one lens 152, 153.

Further illustrated is attachment plate 1715 (i.e., retainer 215), whichincludes threads 151 a and passthrough 220. Threads 151 a, similar tothreads 151, engage threads 117 in housing 110 to allow attachment plate1715 (retainer 215) to engage dome lens 140.

Passthrough 220 includes surface 810 that was disclosed with regard toFIG. 8 .

In accordance with the principles of the invention, threads 151 a onattachment plate 1715 engage threads 117 until surface 810 engages domelens 140. Threads 151 b on attachment section 1725 may similarly engagethreads 117 to retain lens assembly and housing 110 together.

As previously discussed, heat generated by LED 115/PCB 210 istransferred through attachment plate 1715 and attachments section 1725to be dispersed to the environment by lens assembly 1750.

FIG. 18 illustrates a cross-sectional view of a second exemplaryembodiment of a PCB/LED assembly similar to the configuration shown inFIG. 12C.

In this illustrated embodiment, lighting element 112, aperture holder oraperture plate 120 is positioned atop PCB 210, wherein a portion of LED115, on PCB 210, passes through passthrough 125, as previouslydiscussed. Aperture holder 120 partially blocks light generated by thephosphorus section (border 114) of LED 115 from being visible. Furthershown is aperture 130, contained within grooves or slots 330 of apertureplate 120. Aperture 130 includes passthrough 135, which is sized suchthat LED 115 is prevented from extending into passthrough 135.

Further, shown in FIG. 18 , is dome lens 140 positioned on a surface ofaperture holder 120, as aperture 130 is contained entirely within groove330. In an alternate embodiment, dome lens 140 may similarly bepositioned on aperture 130 by sizing aperture 130 to be of a greaterdepth than groove 332 of aperture holder 120.

In summary, a lighting element for providing a brighter light outputusing new generation LEDs is disclosed. By incorporating an LED withinor at the focal length of the dome lens that is placed on or in closeproximity to the LED without glue or adhesive, the LED light output isfocused (or de-focused) and concentrated onto a projection lens. Furtherdisclosed is a light assembly including a housing incorporating thelighting element therein and a lens assembly, that is constructed toattach to the housing and concurrently retaining the dome lens on or inclose proximity to the LED without glue or adhesive. In accordance withthe principles of the invention, the LED is positioned within a focallength of a projection lens within the lens assembly. By defocusing theLED light output, using both a close dome lens and a far-away projectionlens, a brighter and more defined, substantially uniform, light outputis achieved. Also disclosed is a method for mounting the dome lens ontothe LED to satisfy the positional relationship between the LED and thedome lens.

Although the present invention has been described about an eyeglassconfiguration, it would be recognized that the lighting element 112(assembly 100) described herein may be applied to other types ofheadwear configurations. For example, a headband including one or morelens or a monocular assembly (which are referred to herein as eyewear)may incorporate the lighting element 112 (assembly 100) describedherein. Furthermore, although a user wearable device is discussed, itwould be appreciated that the principles of the invention may be appliedto other types of lighting sources. For example, overhead lightingsources, flashlights, etc., incorporating a lighting element 112(assembly 100) in accordance with the principles of the invention havebeen contemplated and within the scope of the invention claimed.Although an LED type light is contemplated and discussed with thelighting element 112 described herein, it would be recognized that othertypes of lighting sources may be utilized without altering the scope ofthe invention claimed.

The invention has been described with reference to specific embodiments.One of ordinary skill in the art, however, would recognize that variousmodifications and changes can be made without departing from the scopeof the invention as set forth in the claims. Accordingly, thespecification is to be regarded in an illustrative manner, rather thanwith a restrictive view, and all such modifications are intended to beincluded within the scope of the invention.

Benefits, other advantages, and solutions to problems have beendescribed above about specific embodiments. The benefits, advantages,and solutions to problems, and any element(s) that may cause anybenefits, advantages, or solutions to occur or become more pronounced,are not to be construed as a critical, required, or an essential featureor element of any or all the claims.

As used herein, the terms “comprises”, “comprising”, “includes”,“including”, “has”, “having”, or any other variation thereof, areintended to cover non-exclusive inclusions. For example, a process,method, article or apparatus that comprises a list of elements is notnecessarily limited to only those elements but may include otherelements not expressly listed or inherent to such process, method,article, or apparatus. In addition, unless expressly stated to thecontrary, the term “of” refers to an inclusive “or” and not to anexclusive “or”. For example, a condition A or B is satisfied by any oneof the following: A is true (or present) and B is false (or notpresent); A is false (or not present) and B is true (or present); andboth A and B are true (or present).

The terms “a” or “an” as used herein are to describe elements andcomponents of the invention. This is done for convenience to the readerand to provide a general sense of the invention. The use of these termsin the description herein should be read and understood to include oneor at least one. In addition, the singular also includes the pluralunless indicated to the contrary. For example, reference to acomposition containing “a compound” includes one or more compounds. Asused in this specification and the appended claims, the term “or” isgenerally employed in its sense including “and/or” unless the contentclearly dictates otherwise.

All numeric values are herein assumed to be modified by the term“about,” whether explicitly indicated. The term “about” generally refersto a range of numbers that one of skill in the art would considerequivalent to the recited value (i.e., having the same function orresult). In any instances, the terms “about” may include numbers thatare rounded (or lowered) to the nearest significant figure.

It is expressly intended that all combinations of those elements thatperform substantially the same function in substantially the same way toachieve the same results are within the scope of the invention.Substitutions of elements from one described embodiment to another arealso fully intended and contemplated.

What is claimed is:
 1. A lighting device comprising: a light housingcomprising: a light emitting diode configured to: emit a light; anelectronic circuit configured to: control a voltage applied to saidlight emitting diode; an aperture holder comprising: a base element; across-shaped recess within said base element; and a first passthroughwithin said base element, said first passthrough being sized to allowsaid light emitting diode to passthrough said first passthrough; across-shaped aperture positioned within said recess of said baseelement, wherein a top surface of said aperture is substantially flushwith a top surface of said base element of said aperture holder, saidaperture comprising: a second passthrough, said second passthrough sizedto limit said light emitting diode from extending into said secondpassthrough; a first lens, comprising a known focal length, said firstlens in contact with said aperture, wherein said light emitting diode ispositioned within said known focal length of said first lens; and aretainer configured to: retain said first lens in position.
 2. Thelighting device of claim 1, wherein the first lens comprises: ahemi-spherical cap.
 3. The lighting device of claim 2, furthercomprising: an anti-reflective layer on at least one surface of saidfirst lens.
 4. The lighting device of claim 1, wherein said firstpassthrough is one of: substantially square and substantially circular.5. The lighting device of claim 1 wherein said second passthrough is oneof: substantially square and substantially circular.
 6. The lightingdevice of claim 1, wherein said light emitting diode comprises: at leasta blue light emitting diode (LED).
 7. The lighting device of claim 6,wherein said blue LED is positioned on a phosphor layer.
 8. The lightingdevice of claim 1, comprising: a lens housing configured to: attach tosaid light housing, said lens housing comprising: at least oneprojection lens, wherein said light emitting diode is within a focallength of said at least one projection lens.
 9. A light assemblycomprising: a lighting device comprising: a light emitting diodeelement, said light emitting diode element comprising at least a blueLED; an aperture holder comprising: a recess; and an aperture holderpassthrough, wherein said light emitting diode element is positionedwithin the aperture holder passthrough; an aperture positioned withinsaid recess, wherein a top surface of said aperture is substantiallyflush with a top surface of said aperture holder, said aperturecomprising: an aperture passthrough, said aperture passthrough beingsized such that only a center section of the light emitting diodeelement is viewable through said aperture passthrough; and a dome lenspositioned on said top surface of said aperture holder in contact withsaid aperture, wherein said light emitting diode is within a focallength of said dome lengths; and a lens housing configured to attach tosaid lighting device, said lens housing comprising: at least oneprojection lens, wherein said light emitting diode element is positionedwithin a focal length of said at least one projection lens.
 10. Thelight assembly of claim 9, wherein said aperture holder passthrough isone of: substantially circular and substantially square.
 11. The lightassembly of claim 9 wherein said aperture passthrough is one of:substantially circular and substantially square.
 12. The light assemblyof claim 9 comprising: a retainer, said retainer comprising a retainerpassthrough, wherein said retainer passthrough contacts said dome lens.13. The light assembly of claim 12, wherein said retainer is integral tosaid lens housing.
 14. The light assembly of claim 9, wherein said blueLED is positioned on a phosphorus layer.
 15. The light assembly of claim9, comprising: a power assembly configured to connect to said lightassembly, said power assembly comprising: a battery configured to:output a voltage; and an electronic circuit configured to: apply saidvoltage to said light emitting diode.
 16. The light assembly of claim10, comprising: a switch configured to: provide an indication to saidelectronic circuit to control said application of said voltage to saidlight emitting diode.
 17. The light assembly of claim 16, wherein saidswitch is one of: a toggle switch, a capacitive touch switch and anon-contact switch.